Web splicing



Oct. 9, 1945. oQc. ROESEVN 'WEB'SPLICING 2 Sheets-Sheet 1 Filed April 14, 1943 INVENTOR- I ATTORNEYS Ogt. 9, 1945. -o. c; ROESEN I 2,386,344

WEB SPLIC-ING Filed April 14, 1943 2 Sheets-Sheet 2 Patented Oct. 9;, 1945 TENT lll Claims.

This invention relates to the splicing of webs and more particularly concerns the splicing of the leading or outer end of the web on a new or replacement web roll to the' core or inner end of a similar web from another roll while the latter is running to a printing press or other web consuming mechanism.

The paper or other flexible 'web fed to a printing press, wrapping machine, paper roll winding machine, or other web consuming mechanism is fed from rolls which must be replaced periodically as they are consumed. It is, of course, desirable that the roll replacement be made without stopping or retarding the operation of the web consuming apparatus. It is further desirable that the old or expiring web roll be substantially completely used before the running web is spliced to that on the new roll, since this avoids wasting the web material.

High speed web roll changing has heretofore been accomplished by mechanism in which a new r'oll bearing a layer of adhesive at its leading edge is accelerated to the speed of the running web, and thereafter, when the roll supplying the running web has been consumed to. a point near its end, the running web is pressed against the periphery of the new roll, the splice being made when the adhesive on the new web contacts the running web, and. the web from the expiring roll is thereafter severed. The point at which the splice is made is customarily judged by the operator, and since failure to splice on a new roll before thhe old roll runs out seriously delays operation of the web consuming mechanism, the operator usually splices when there'is still an ample reserve of web left on the old roll. The amount of web thus wasted by splicing before the end of the web has run off the old roll is considerable.

By the method and apparatus described and claimed in my copending application, Serial No. 403,515, filed July 22, 1941, now Patent No. 2,320,- 656, a web roll may be replaced without substantial wastage of web from the expiring roll, since the point in the running of the old roll at which the splice is made is determined by the part thereof that bears a layer of special self-sticking adhesive. However, that method and the above described older splicing methods may leave a considerable overlap, or tail of the old web trailing behind the point where the old and new webs are spliced together. Such a long tail is undesirable in that products such as printed pages, wrappers, etc., formed by the web consuming apparatus from 'the double thickness web must be discarded. Further, a web tail of considerable length is undesirable in that it frequently flies out from the running web, particularly at points where the web turns at sharp angles in its passage through the press orother apparatus, with the result that the tail becomes fouled with another section of the web or other mechanism. This frequently results'in breakage of the running web or other disruption of its passage through the mechanism with resultant relay of operation and wastage of web material.

With the above and other considerations in mind, it is proposed in accordance with the present invention to provide an improved method of and apparatus for splicing the leading end of a web on a new or replacement web roll to the inner or core end of a web running from a depleted roll in which the running web is severed so close to the point of juncture of the old and new webs that no substantial tail of the old web trails behind the splice, and in which premature splicing and consequent wasting of web on the old roll is avoided.

In general, the above and other objects of the invention are carried out by the use of means on the new or old webs or both that actuate controls and so govern the web severing operation. In one embodiment of the invention, a control actuator is provided on the running web adjacent the core end thereof'and a second actuator is provided on the periphery of the new roll. The actuators cooperate with stationary control devices adjacent the web to sever the running web at the instant the splice is made and at a point close to the splice. The control actuator on the web is employed in conjlmction with an adhesive coated area and is so positioned with respect thereto that as soon as this area comes in contact with the periphery of the new web roll, the control actuator on the running web is effective. The control actuator 0n the periphery of the new roll is so positioned that as soon as the adhesive bearing leading edge of the web on that roll contacts the adhesive bearing area of the running web the new rollcontrol actuator is efiective. When both such control actuators thus become efiective, indicating that the splice is made, the old web is severed close to the splice. In a modified form of the invention, the control actuator on the running web is employed to operate mechanism for pressing the running web against the periphery of the new web roll when the old web roll is substantially consumed, and the control actuator on the periphery of the new web roll thereafter acts to cause severing. of, the

web when the adhesive bearing leading edge of the new web comes in contact with the running web.

In describing the invention in detail, reference will be made to the accompanying drawings, in which certain typical embodiments of the invention are diagrammatically illustrated. In the drawings:

Fig. '1 is a diagrammatic elevation illustrating apparatus embodying the invention as applied to a web splicing operation employing a self-sticking adhesive;

Fig. 2 is a perspective view of a new web roll for use in the apparatus of Fig. 1;

Fig. 3 is a plan view of a section of web cent the core end of the web roll;

Fig. 4 is an enlarged diagrammatic sectional view of one of the control actuator responsive devices used in the modification of Fig. 1;

Fig. 5 is a partial perspective view showing a modified form of the apparatus illustrated in Fig.

Fig. 6 is a diagrammatic elevation of apparatus adjaembodying a modified form of the invention as applied to a web splicing operation of the conventional type;

Figs. '7 and 8 are partial diagrammatic elevations of the. apparatus shown in Fig. 6, illustrating the operation of the apparatus when a splice is being made; and

Fig. 9 is a fragmentary elevation of the core end of a web suitable for use in the modification illustrated in Fig. '7.

Referring to Fig. 1, there is illustrated a conventional three-roll reel II which is rotatable about a central axis l2 and carries three web roll spindles 13, I4, and [5 at the ends of its arms.

As shown, the spindles l3 carry a web roll l5 that is substantially consumed, and new web rolls H and I8 are respectively mounted on the spindles l4 and 15. A set of conventional tension belts extends parallel to the roll surfaces around the idler rollers 20, 2|, 22, 23 and 24 and the driving roller 25, and a weighted or otherwise biased idler roller 26 maintains the belts l9 at the desired tension. The belts I3 are preferably driven at a speed substantially equal to that of the running web 21 by suitable means such as a shaft 28 connected with the press or other web consuming apparatus. The belts l9 are preferably narrower than the web 21, as shown in Fig. 5, and are spaced apart transversely of the web in accordance with conventional practice. shown running from the expiring roll l6, travels over a guide roller 29 to a press or other web consuming apparatus, not shown.

It should be understood that the web may be paper, cloth, or any other relatively thin flexible material. Each new roll of this web for use in the modification of Figs. 1 through 5 is provided with a layer of self-sticking adhesive 33 on its outer surface at its leading edge, and this edge is removably secured to the underlying layer of web on the roll by suitable means such as frangible gummed tabs 3| having a central weakened portion such as a line of perforations 32. Tabs of this type are described in detail in United States Patent No. 1,996,497.

The adhesive comprising the layer 30, which will be hereinafter referred to as a self-sticking adhesive, is of the nature of a rubber cement. Adhesives of this type are described in detail in The web 21,

my copending application Serial No. 403,515, filed Patent No. 2,320,656. As there explained, this self-sticking adhesive has the properties of adhering tenaciously to the paper or other web when applied thereto in liquid form, but when dried does not adhere to an uncoated web surface. The dried self-sticking adhesive coatings cohere tenaciously with similarly applied and dried coatings.

The core end of each web roll carries a layer 33 of the self-sticking adhesive on its inner surface as illustrated in Figs. 1 and 3. This layer 33 extends across the entire width of the web except for a longitudinally extending area 34 which may be near one edge of the web as shown. The

layer 33 of adhesive extends longitudinally of the web for a distance at least equal to the circumference of the largest new web roll employed. A control actuator which may take the form of a black or other dark-colored strip or mark 35 extends longitudinally of the web within or in alignment with the bare area 34, and the leading end of this control actuator is spaced rearwardly of the web from the leading end of the adhesive area 33 by a predetermined distance as hereinafter explained. The trailing end of the control actuator 35 extends a like distance behind the trailing edge of the adhesive coated area 33. Thus the adhesive coating 33 and the control actuator 35 are of equal extent longitudinally of the web, but the adhesive coating leads the control actuator by a predetermined interval. The control actuator strip may be printed or otherwise applied on either surface of the web and is preferably applied to its outer surface. I

Each new roll has a control actuator on its outer periphery located at a predetermined posi-' tion relative to the adhesive bearing leading end of the web. In the illustrated embodiment this control actuator takes the form of a short black or dark' strip or mark 36 disposed adjacent one edge of the web substantially diametrically opposite the leading end of the web that carries the layer 30 of self-sticking adhesive.

Suitable control actuator responsive devices are provided for governing the severing of the web in response to the web carried control actuators 35 and 3B. In the embodiment illustrated in Figs.

1 through 4, these take the form of photoelectric portion of the projected beam that is reflected from the web. One such device D is diagrammatically illustrated in Fig. 4 and includes a housing 31' containing alight source 38, the light from which is columnated by a lens 39 and projected through a window 40 onto the web 21, the reflected beam entering another window 4| and acting on a photoelectric cell 42. A relay 43 is energized and so opens its contacts 44 so long as a predetermined amount of reflected light acts on the photoelectric cell 42. When the intensity of the reflected light is materially reduced, as by movement of one of the control actuators 35 or 36 past the scanning device, the relay 43 is tie-energized and its contacts 44 close. It should be understoodthat the scanning device may include an amplifier for the photoelectric cell current and other known refinements, the illustration of which is not necessary to an understanding of the present invention.

One scanning device D of the type described is disposed adjacent the outer surface of the running web 21 in line with the control actuator 35 thereon and close to the point where the running so that rotation of the reel in the direction of the arrow will push the frame. to the right and prevent contact between the scanning device D and the web.

A web severing knife 49 of conventional design is pivotally mounted on the frame 45 and is arranged to' be swung outwardly to sever the web by energization of a solenoid 50 as will be evident by reference to Figs. 1 and 5.

A second scanning device D' is suitably mounted adjacent the surface of the new web roll I! occupying the replacement position, as shown in Fig. 1. This device D is aligned with the control actuator 36 on the periphery of the new web roll and is preferably mounted in any suitable movable support permitting its removal from the path of the rolls when the reel II is rotated.

When the roll Hi from which the web 2'! is running to the web consuming apparatus becomes depleted so that it is necessary to make a splice, the reel H is turnedto the position shown in Fig. 1 with the running web 21 passing in contact with the surface of the new roll H in the replacement position. Passage of the running web 21 backed up by the belts l9, over the surface of the new roll I! accelerates it to a speed at-which its peripheral velocity equals the running web speed. During this acceleration, the self-sticking adhesive layer 30 at the leading edge of the web on the new roll I! does not stick to the running web 21 because of the above described characteristics of this adhesive. When the old roll it is consumed, the adhesive bearing area 33 at the core end thereof approaches the new roll ll. At the instant that the leading edge of this area 33 contacts the periphery of the new roll ill, the control actuator 35 moves in front of the scanning device D and so reduces the reflected beam therefrom that the contacts M of this device close. The distance between the lead,- ing end of the control actuator 35 and the leading edge of the core end adhesive layer 33 is arranged to equal the distance between the scanning device D and the point of tangency of the running web El and the new roll surface. Thereafter, as soon as the control actuator 36 on the new roll comes opposite the second scanning device I), indicating that the adhesive layer 30 at the leading edge of the new roll web has come in contact with the adhesive bearing area 33 on the running web 21 to make the splice, the contacts of the device D close and a series circuit is thereby completed, energizing the solenoid 50 from a source of electrical energy through the relay contacts of both of the scanning devices D and D. Energization of the solenoid 513 moves the knife 39 into the running web, thus severing the web just after the splice is made and close to the splice, whereby a long tail of web trailing behind the splice is avoided.

The splice is made by the tenacious coherence between the self-sticking adhesive bearing areas 30 and 33. This coherence causes the running web to pull the leading end of the web on the new roll il away from the roll surface, tearing the frangible tabs 3| along their weakened center lines 32. After the splice is made and the old web is cut, the web from the new roll ll becomes the running web and the reel II is turned in the direction of the arrow to move this roll to a suitable running position, usually intermediate between the positions in which the rolls l8 and II are shown in Fig. 1. When a' further roll replacement is necessary, the reel is turned to move the running roll to the lower position shown, moving the next new roll l8 into the replacement position, and the above described operation is repeated.

It is not essential that photoelectric scanning devices be employed and various means may be used for controlling the web severing operation in accordance with the position of the running web. For example, in a modified form of the invention illustrated in Fig. 5, the control actuator 35' adjacent the core end of the running web 21' and the control actuator 36' on the periphery of the new web roll l1 comprise electrically conductive layers such as stripes of metallic paint or applied strips of metal foil or other conductive material. In this modification, the control actuator responsive means comprise stationary pairs of brushes mounted adjacent the webs. The brushes 52 are arranged to contact the running web 21' in line with the control actuator 35 and the brushes 53 aremounted to contact the peripheral surface of the new roll IT in line with the control actuator 36. The brushes 52 and 53 of each set are connected in series with each other, with the knife solenoid Eli and the source of electrical energy lit. The operation of the described apparatus of Fig. 5 in making a splice and cutting the old web is the same as that described above in connection with Fig. 1.

In a modified form of the invention, illustrated in Figs. 6 through 9, the use of control actuators on the web is applied to a conventional splicing operation to prevent wastage of web by premature splicingand to limit the length of the tail of old web at the splice.

Referring to Fig. 6 there is illustrated a conventional three-roll reel 56 carrying a substantially depleted roll '55, a new roll 56 in replacement position, and another new roll 51. The leading edge of the web on each new roll carries a layer 58 of ordinary tacky adhesive and is removably secured to the roll surface by suitable means such as the frangible gummed tabs 59. A control actuator tn which, as shown, may comprise a black or dark strip extending longitudinally of the web is disposed substantially diametrically opposite the adhesive carrying leading end of the new roll web. A scanning devise S of the type described above is mounted to be disposed adjacent the new roll at opposite the point where the splice is to be made.

The core end -of the web on each roll carries a control actuator ti comprising a longitudinally extending black or dark-colored strip as illustrated in Fig. 9. This control actuator extends longitudinally of the web for a distance at least as long as the circumference of the largest new roll employed. The new roll may be accelerated to web speed by any known means that drives the roll through the reel spindle or by surface contact. As shown, drive belts 62 running over idler rolls 63 and 6t and drive rollers 65 are provided to engage the surface of the new roll 56 and accelerate it to web speed. Where belts are used for this purpose suitable gaps are provided in the adhesive layer 58, and the belts 62 are spaced transversely of the web in alignment with such gaps according to the known practice in this art. The drive belts 62 are carried by a movable frame which may be pivoted at 66 and biased by a spring I to press the belts onto the roll surface. The drive rollers 65 are driven at a peripheral velocity corresponding to the running web speed through a suitable drive connection such as the chains 58 and 59 and the sprocket III.

A paster frame I I: is pivotally secured to a fixed support I2 and carries the usual brush I3 and web severing knife I4. A solenoid I acts when energized to extend the brush I3 and so press the running web I6 into contact with the surface of the new roll 56. A solenoid II acts when energized to move the knife [4 into the running web and so sever it. A scanning device S' or other means responsive to the web carried control Aactuator is also mounted on the frame Ii.

When a running roll nears depletion the reel is moved to the position shown in Fig. 6 and the frame II is lowered to the splicing position as indicated. The drive belts 62 are brought into contact with the new roll 56 and they accelerate it to web speed. When the running roll 55 is substantially depleted, the control actuator 5| moves opposite the scanning device S and so closes the contacts of that device. This energizes the brush solenoid I5 from the source of electrical energy I8 through a circuit which is clear from the drawings. The brush I3 is then extended and presses the running web I6 into firm engagement with the surface of the new roll 56, as shown in Fig. '7. Thereafter, when the control actuator 60 comes opposite the scanning device S, indicating that the adhesive bearing area 58 at the leading edge of the new roll web is in contact with the running web 16, the contacts of the device S close and energize the knife solenoid II from the source of energy I8 through a circuit including the contacts of the device S as clearly shown in the drawings. This extends the knife 14 and severs the web at the instant the splice is made by contact of the running web with the adhesive bearing leading edge of the new web (Fig. 8). As the splice is made the frangible tabs 59 are broken and the leading end of the new roll web runs off and becomes the running web. Thereafter, the paster frame H and the drive belt frame 80 are retracted, the scanning device S is moved out of the path of the reel, and the reel is rotated to a position in which the new roll 56 is at a point between the positions in which the rolls 55 and 56 are shown in the drawings. The above described operation is repeated whenever a roll is used up.

Obviously, the scanning devices S and S may be replaced by pairs of electrical contact brushes, in which event the control actuators 58 and 60 will comprise conductive strips rather than black or darkened strips on the web.

In some cases the apparatus of Fig. 6 may be employed with web rolls that do not have a control actuator 6| adjacent the core ends of the webs. In this situation, the scanning device S' may be inactive or may be dispensed-with, and the energizing circuit for the brush operating solenoid I5 may be closed by a suitable manually operable switch or push button illustrated at 8! in Fig. 6. With this arrangement, the operator closes the push button switch 8| when in his judgment the expiring roll 55 has about run out. Closure of the push button switch 8! ener izes the solenoid I5 through a; circuit that is apparent from the drawings, and the brush I3 then presses the running web 16 against the surface-of the new roll 56. Thereafter, as soon as the control actuator 60 passes the scanning device S, indicating that the adhesive bearing leading end of the new roll web is in splicing contact with the running web, the knife solenoid II is energized through the push button switch BI and the contacts of the scanning device S and the knife I4 is extended to -cut the web close to the splice.

I claim:

1. In a method of splicing the leadin end of a web on a new roll to a web running at a constant high speed from an expiring roll in which a layer of adhesive on the leading end of the web on the new roll is stuck to the web running from the expiring roll to make a splice, the improvement comprising providing a control actuator on and adjacent the core end of the web running from the expiring roll, and severing the web running 7 from the expiring roll in response to the approach of said control actuator to a point adjacent said new roll, indicating that the web on the expirin roll is substantially consumed and to the angular position of the new roll, indicating that the splice has been made.

2. In a method of splicing the leading end of a web on a new roll to a web running from an expiring roll in which a layer of adhesive on the leading end of the web on the new roll is stuck to the web running at a constant high speed from an expiring roll to make a splice, the improvement comprising providing a control actuator on the web running from the expiring roll adjacent its inner end, providing a control actuator on the surface of the new roll, accelerating the new roll to running web speed, and severing the web running from the-expiring roll in response to both movement of the control actuator on such web to a position adjacent the new roll indicating that the expiring roll is substantially completely consumed and movement of the control actuator on said new roll to a position indicating that the web from the new roll has been stuck to the running web.

3. In apparatus forsplicing the leading end of the web on a new roll to a web running past the cylindrical surface of the new r011 from an expiring roll after the new roll is accelerated to running web speed, the combination with means for severin the running web after the splice is made of a control actuator onthe new roll surface and a control actuator on the running web adjacent the core end thereof, and means governed by both of said control actuators for governing the operation of said web severing means.

4. In apparatus for splicing the leading end of the web on a new roll to a web running past the cylindrical surface of the new roll from an expiring roll after the new roll is accelerated to running web speed, in combination, a control actuator on the web running from the expiring roll I adjacent the core end thereof, a control actuator on the surface of the new roll and means responsive to both said control actuators for severing the web running from the expirin roll when the control actuator on the running web approaches the new roll and the control actuator on the new roll reaches a position indicating that the running web is'in contact with the leading end of the new roll web.

5. In apparatus for splicing the leading end of the web on a new roll to a web running past the cylindrical surface of the new roll from an ex piring roll after'the new roll is accelerated to running web speed, means on the web running from the expiring roll adjacent its core end for closing an electrical circuit when said end of the said web approaches the new roll. means on the surface of the new roll for closing an electrical circuit when the leading end of the web on the new roll contacts the running web and means responsive to the operation of both of said circuit closing means for severing the web running from the expiring roll.

6. In apparatus for splicing the leading end of the web on a new roll to a web running in contact with the new roll surface from an expiring roll, in combination with a layer of self-sticking adhesive on the leading end of the new roll web and a layer of self-sticking adhesive adjacent the core end of the expiring roll web, a control actuator on the expiring roll web adjacent the adhesive layer thereon, a control actuator on the surface of the new roll, and, means responsive to both of said control actuators for severing the web running from the expiring roll to the new roll when said control actuator on the running web approaches the new roll and so indicates that the adhesive layer on such web is in contact with the new roll surface and said control actuator On the new roll reaches a position indicating that the adhesive layer on the new roll web is in contact with the running web.

7. In apparatus for splicing the leading end of the web on a new roll to a web running in contact with the new roll surface from an expiring roll, in combination with a layer of self: sticking adhesive on the leading end of the new roll web and a layer of self-sticking adhesive adjacent the core end of the expiring roll web and extending longitudinally of said web a distance at least equal to the circumference of the new roll, means on said running web adjacent said adhesive layer thereon for closing electrical contacts when said adhesive layer is in contact with said new roll surface, means responsive to the angular position of the new roll for closing electrical contacts when the adhesive layer 'on the leading edge of the new roll is in contact with the expiring roll to the new roll when both of said contact closing means are operative.

9. In apparatus for splicing the leading end of the web on a new roll to a web running in contact with the new roll surface from an expiring roll, in combination with a layer of self-sticking adhesive on the leading end of the new roll web and a layer of self-sticking adhesive adjacent the core .end of the expiring roll web, a control actuator on said running web adjacent the adhesive layer thereon and extending longitudinally of said web for a distance at least equal to the circumference of the new roll, a control actuator on the surface of said new roll at a point spaced from the leading end of the new roll web, and means responsive t'oboth the movement of said running web carried control actuator to a position indicating contact between the adhesive layer on said running web and the surface of the new roll and the movement of said new roll carried control actuator to a position indicating contact between the adhesive layers on the new roll .web and the running web for severing the running web approaching the new roll.

10. In apparatus for splicing the leading end of the web on a new roll to a web running past the cylindrical surface of the new roll from an expiring roll after the new roll is accelerated to running web speed, the combination, with means for severing the running web after the splice is made, of a mark having different light reflecting properties than the web located on the web running from the expiring roll adjacent the core end of said web, a mark having different light reflecting properties than the web located on the cylindrical surface of the new roll at a predetermined distance from the leading end of the web thereon, stationary light responsive means adjacent the web running from the expiring roll 40 and responsive to the passage of said running running web, and means for severing the web running from the expiring roll to the new roll when both said contact closing means operate.

8. In apparatus for splicing the leading end of the web on a new roll to a web running in contact with the new'roll surface from an expiring roll, in combination with a layer of self-sticking adhesive on the leading end of the new roll .web and a layer of self-sticking adhesive adjacent the core end of the expiring roll web and extending longitudinally of said web a distance at least equal to the circumference of the new roll, a

control actuator on said running web adjacent the adhesive layer thereon and extending lon itudinally of said web for a distance at least equal to the circumference of the new roll, a control actuator on the surface of said new roll at a point spaced from th leading end of the new roll web, means adjacent the running web between the expiring roll and the new roll for' web mark, stationary light responsive means adjacent the cylindrical surface of the new roll responsive to the passage of said new roll mark,

and mechanism controlled by both of said light. responsive means for governing the operation ofsaid web severing means.

. 11. In apparatus for splicing the leading end of the web on a new roll to a web running past the cylindrical surface of the new roll from an expiring roll after the new roll is accelerated to running web speed,- the combination, with means for pressing the running web against the new roll surface and means for severing the running web when said control actuator on said new roll passes said device.

OSCAR C. ROESEN. 

